Expanding a tubular member

ABSTRACT

A tubular member is expanded by pressurizing an interior region within the tubular member.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of the filing date ofU.S. provisional patent application Ser. No. 60/183,546, attorney docketno. 25791.10, filed on Feb. 18, 2000, the disclosure of which isincorporated herein by reference.

[0002] This application is a continuation-in-part of U.S. Ser. No.09/559,122, attorney docket number 25791.23.02, filed on Apr. 26, 2000,which claimed the benefit of the filing date of U.S. provisional patentapplication Ser. No. 60/131,106, filed on Apr. 26, 1999, which was acontinuation-in-part of U.S. patent application Ser. No. 09/523,460,attorney docket number 25791.11.02, filed on Mar. 10, 2000, whichclaimed the benefit of the filing date of U.S. provisional patentapplication Ser. No. 60/124,042, filed on Mar. 11, 1999, which was acontinuation-in-part of U.S. patent application Ser. No. 09/510,913,attorney docket number 25791.7.02, which claimed the benefit of thefiling date of U.S. provisional patent application Ser. No. 60/121,702,filed on Feb. 25, 1999, which was a continuation-in-part of U.S. patentapplication Ser. No. 09/502,350, attorney docket number 25791.8.02,filed on Feb. 10, 2000, which claimed the benefit of the filing date ofU.S. provisional patent application Ser. No. 60/119,611, attorney docketnumber 25791.8, filed on Feb. 11, 1999, which was a continuation-in-partof U.S. patent application Ser. No. 09/454,139, attorney docket number25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of thefiling date of U.S. provisional patent application Ser. No. 60/111,293,filed on Dec. 7, 1998.

[0003] The present application is related to the following U.S. patentapplications: (1) utility patent application number ______, attorneydocket number 25791.9.02, filed on Nov. 16, 1999, which claimed thebenefit of the filing date of provisional patent application No.60/108,558, attorney docket number 25791.9, filed on Nov. 16, 1998; (2)utility patent application number ______, attorney docket number25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of thefiling date of provisional patent application No. 60/111,293. attorneydocket number 25791.3, filed on Dec. 7, 1998; (3) utility patentapplication number ______, attorney docket number 25791.8.02, filed onFeb. 10, 2000, which claimed the benefit of the filing date ofprovisional patent application No. 60/119,611, attorney docket number25791.8, filed on Feb. 11, 1999; (4) provisional patent application No.60/121,702, attorney docket number 25791.7, filed on Feb. 25, 1999; (5)provisional patent application No. 60/121,841, attorney docket number25791.12, filed on Feb. 26, 1999; (6) provisional patent application No.60/121,907, attorney docket number 25791.16, filed on Feb. 26, 1999; (7)provisional patent application No. 60/124,042, attorney docket number25791.11, filed on Mar. 11, 1999; (8) provisional patent application No.60/131,106, attorney docket number 25791.23, filed on Apr. 26, 1999; (9)provisional patent application No. 60/137,998, attorney docket number25791.17, filed on Jun. 7, 1999; (10) provisional patent application No.60/143,039, attorney docket number 25791.26, filed on Jul. 9, 1999; (11)provisional patent application No. 60/146,203, attorney docket number25791.25, filed on Jul. 29, 1999; (12) provisional patent applicationNo. ______, attorney docket number 25791.29, filed on Sep. 16, 1999;(13) provisional patent application No. ______, attorney docket number25791.34, filed on Oct. 12, 1999; (14) provisional patent applicationNo. ______, attorney docket number 25791.36, filed on Oct. 12, 1999;(13) provisional patent application No. 60/159,033, attorney docketnumber 25791.37, filed on Oct. 12, 1999; (15) provisional patentapplication No. ______, attorney docket number 25791.27, filed on Nov.01, 1999. Applicants incorporate by reference the disclosures of theseapplications.

BACKGROUND OF THE INVENTION

[0004] This invention relates generally to wellbore casings, and inparticular to wellbore casings that are formed using expandable tubing.

[0005] Conventionally, when a wellbore is created, a number of casingsare installed in the borehole to prevent collapse of the borehole walland to prevent undesired outflow of drilling fluid into the formation orinflow of fluid from the formation into the borehole. The borehole isdrilled in intervals whereby a casing which is to be installed in alower borehole interval is lowered through a previously installed casingof an upper borehole interval. As a consequence of this procedure thecasing of the lower interval is of smaller diameter than the casing ofthe upper interval. Thus, the casings are in a nested arrangement withcasing diameters decreasing in downward direction. Cement annuli areprovided between the outer surfaces of the casings and the borehole wallto seal the casings from the borehole wall. As a consequence of thisnested arrangement a relatively large borehole diameter is required atthe upper part of the wellbore. Such a large borehole diameter involvesincreased costs due to heavy casing handling equipment, large drill bitsand increased volumes of drilling fluid and drill cuttings. Moreover,increased drilling rig time is involved due to required cement pumping,cement hardening, required equipment changes due to large variations inhole diameters drilled in the course of the well, and the large volumeof cuttings drilled and removed.

[0006] Conventionally, at the surface end of the wellbore, a wellhead isformed that typically includes a surface casing, a number of productionand/or drilling spools, valving, and a Christmas tree. Typically thewellhead further includes a concentric arrangement of casings includinga production casing and one or more intermediate casings. The casingsare typically supported using load bearing slips positioned above theground. The conventional design and construction of wellheads isexpensive and complex.

[0007] Conventionally, a wellbore casing cannot be formed during thedrilling of a wellbore. Typically, the wellbore is drilled and then awellbore casing is formed in the newly drilled section of the wellbore.This delays the completion of a well.

[0008] The present invention is directed to overcoming one or more ofthe limitations of the existing procedures for forming wellbores andwellheads.

SUMMARY

[0009] According to another embodiment of the present invention, amethod of expanding a tubular member is provided that includes placing amandrel within the tubular member, pressurizing an annular region withinthe tubular member above the mandrel, and displacing the mandrel withrespect to the tubular member.

[0010] According to another embodiment of the present invention, anapparatus for radially expanding a tubular member is provided thatincludes a first tubular member, a second tubular member positionedwithin the first tubular member, a third tubular member movably coupledto and positioned within the second tubular member, a first annularsealing member for sealing an interface between the first and secondtubular members, a second annular sealing member for sealing aninterface between the second and third tubular members, and a mandrelpositioned within the first tubular member and coupled to an end of thethird tubular member.

[0011] According to another embodiment of the present invention, anapparatus is provided that includes a tubular member, a piston adaptedto expand the diameter of the tubular member positioned within thetubular member, and an annular chamber defined by the piston and tubularmember. The piston includes a passage for conveying fluids out of thetubular member.

[0012] According to another embodiment of the present invention, anapparatus is provided that includes a preexisting structure and atubular member coupled to the preexisting structure. The tubular memberis coupled to the preexisting structure by the process of: positioningthe tubular member in an overlapping relationship to the preexistingstructure, placing a mandrel within the tubular member, pressurizing anannular region within the tubular member above the mandrel, anddisplacing the mandrel with respect to the tubular member.

[0013] According to another embodiment of the present invention, amethod of expanding a tubular member is provided that includespreforming the tubular member to include a first portion, a secondportion, and a third portion, placing a mandrel within the secondportion of the tubular member, pressurizing a region within the tubularmember; and displacing the mandrel with respect to the tubular member.The inside diameter of the second portion of the tubular member isgreater than the inside diameters of the first and third portions of thetubular member.

[0014] According to another embodiment of the present invention, anapparatus for radially expanding a tubular member is provided thatincludes a first tubular member, a second tubular member coupled to thefirst tubular member, a third tubular member coupled to the secondtubular member, and a mandrel positioned within the second tubularmember and coupled to an end portion of the third tubular member. Theinside diameter of the second tubular member is greater than the insidediameters of the first and third tubular members.

[0015] According to another embodiment of the present invention, anapparatus is provided that includes a tubular member having first,second, and third portions, a piston adapted to expand the diameter ofthe tubular member positioned within the second portion of the tubularmember, the piston including a passage for conveying fluids out of thetubular member. The inside diameter of the second portion of the tubularmember is greater than the inside diameters of the first and thirdportions of the tubular member.

[0016] According to another embodiment of the present invention, anapparatus is provided that includes a preexisting structure and atubular member coupled to the preexisting structure. The tubular memberis coupled to the preexisting structure by the process of: preformingthe tubular member to include first, second, and third portions,positioning the tubular member in an overlapping relationship to thepreexisting structure; placing a mandrel within the second portion ofthe tubular member; pressurizing an interior region within the tubularmember; and displacing the mandrel with respect to the tubular member.The inside diameter of the second portion of the tubular member isgreater than the inside diameters of the first and third portions of thetubular member.

[0017] The present embodiments of the invention provide methods andapparatus for forming and/or repairing wellbore casings, pipelines,and/or structural supports by radially expanding tubular members. Inthis manner, the formation and repair of wellbore casings, pipelines,and structural supports is improved.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018]FIG. 1a is a fragmentary cross-section illustration of anembodiment of an apparatus and method for expanding tubular members.

[0019]FIG. 1b is another fragmentary cross-sectional illustration of theapparatus of FIG. 1a.

[0020]FIG. 1c is another fragmentary cross-sectional illustration of theapparatus of FIG. 1a.

[0021]FIG. 2a is a fragmentary cross-section illustration of anembodiment of an apparatus and method for expanding tubular members.

[0022]FIG. 2b is another fragmentary cross-sectional illustration of theapparatus of FIG. 2a.

[0023]FIG. 2c is another fragmentary cross-sectional illustration of theapparatus of FIG. 2a.

[0024]FIG. 2d is another fragmentary cross-sectional illustration of theapparatus of FIG. 2a.

[0025]FIG. 2e is another fragmentary cross-sectional illustration of theapparatus of FIG. 2a.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

[0026] Referring now to FIGS. 1a, 1 b and 1 c, an apparatus 100 forexpanding a tubular member will be described. In a preferred embodiment,the apparatus 100 includes a support member 105, a packer 110, a firstfluid conduit 115, an annular fluid passage 120, fluid inlets 125, anannular seal 130, a second fluid conduit 135, a fluid passage 140, amandrel 145, a mandrel launcher 150, a tubular member 155, slips 160,and seals 165. In a preferred embodiment, the apparatus 100 is used toradially expand the tubular member 155. In this manner, the apparatus100 may be used to form a wellbore casing, line a wellbore casing, forma pipeline, line a pipeline, form a structural support member, or repaira wellbore casing, pipeline or structural support member. In a preferredembodiment, the apparatus 100 is used to clad at least a portion of thetubular member 155 onto a preexisting tubular member.

[0027] The support member 105 is preferably coupled to the packer 110and the mandrel launcher 150. The support member 105 preferably is atubular member fabricated from any number of conventional commerciallyavailable materials such as, for example, oilfield country tubulargoods, low alloy steel, carbon steel, or stainless steel. The supportmember 105 is preferably selected to fit through a preexisting sectionof wellbore casing 170. In this manner, the apparatus 100 may bepositioned within the wellbore casing 170. In a preferred embodiment,the support member 105 is releasably coupled to the mandrel launcher150. In this manner, the support member 105 may be decoupled from themandrel launcher 150 upon the completion of an extrusion operation.

[0028] The packer 110 is coupled to the support member 105 and the firstfluid conduit 115. The packer 110 preferably provides a fluid sealbetween the outside surface of the first fluid conduit 115 and theinside surface of the support member 105. In this manner, the packer 110preferably seals off and, in combination with the support member 105,first fluid conduit 115, second fluid conduit 135, and mandrel 145,defines an annular chamber 175. The packer 110 may be any number ofconventional commercially available packers modified in accordance withthe teachings of the present disclosure. In a preferred embodiment, thepacker 110 is an RTTS packer available from Halliburton Energy Servicesin order to optimally provide high load and pressure containmentcapacity while also allowing the packer to be set and unset multipletimes without having to pull the packer out of the wellbore.

[0029] The first fluid conduit 115 is coupled to the packer 110 and theannular seal 130. The first fluid conduit 115 preferably is an annularmember fabricated from any number of conventional commercially availablematerials such as, for example, oilfield country tubular goods, lowalloy steel, carbon steel, or stainless steel. In a preferredembodiment, the first fluid conduit 115 includes one or more fluidinlets 125 for conveying fluidic materials from the annular fluidpassage 120 into the chamber 175.

[0030] The annular fluid passage 120 is defined by and positionedbetween the interior surface of the first fluid conduit 115 and theinterior surface of the second fluid conduit 135. The annular fluidpassage 120 is preferably adapted to convey fluidic materials such ascement, water, epoxy, lubricants, and slag mix at operating pressuresand flow rates ranging from about 0 to 3,000 gallons/minute and 0 to9,000 psi in order to optimally provide flow rates and operationalpressures for the radial expansion process.

[0031] The fluid inlets 125 are positioned in an end portion of thefirst fluid conduit 115. The fluid inlets 125 preferably are adapted toconvey fluidic materials such as cement, water, epoxy, lubricants, andslag mix at operating pressures and flow rates ranging from about 0 to9,000 psi and 0 to 3,000 gallons/minute in order to optimally provideflow rates and operational pressures for the radial expansion process.

[0032] The annular seal 130 is coupled to the first fluid conduit 115and the second fluid conduit 135. The annular seal 130 preferablyprovides a fluid seal between the interior surface of the first fluidconduit 115 and the exterior surface of the second fluid conduit 135.The annular seal 130 preferably provides a fluid seal between theinterior surface of the first fluid conduit 115 and the exterior surfaceof the second fluid conduit 135 during relative axial motion of thefirst fluid conduit 115 and the second fluid conduit 135. The annularseal 130 may be any number of conventional commercially available sealssuch as, for example, O-rings, polypak seals, or metal spring energizedseals. In a preferred embodiment, the annular seal 130 is a polypak sealavailable from Parker Seals.

[0033] The second fluid conduit 135 is coupled to the annular seal 130and the mandrel 145. The second fluid conduit preferably is a tubularmember fabricated from any number of conventional commercially availablematerials such as, for example, coiled tubing, oilfield country tubulargoods, low alloy steel, stainless steel, or low carbon steel. In apreferred embodiment, the second fluid conduit 135 is adapted to conveyfluidic materials such as cement, water, epoxy, lubricants, and slag mixat operating pressures and flow rates ranging from about 0 to 9,000 psiand 0 to 3,000 gallons/minute in order to optimally provide flow ratesand operational pressures for the radial expansion process.

[0034] The fluid passage 140 is coupled to the second fluid conduit 135and the mandrel 145. In a preferred embodiment, the fluid passage 140 isadapted to convey fluidic materials such as cement, water, epoxy,lubricants, and slag mix at operating pressures and flow rates rangingfrom about 0 to 9,000 psi and 0 to 3,000 gallons/minute in order tooptimally provide flow rates and operational pressures for the radialexpansion process.

[0035] The mandrel 145 is coupled to the second fluid conduit 135 andthe mandrel launcher 150. The mandrel 145 preferably are an annularmember having a conic section fabricated from any number of conventionalcommercially available materials such as, for example, machine toolsteel, ceramics, tungsten carbide, titanium or other high strengthalloys. In a preferred embodiment, the angle of the conic section of themandrel 145 ranges from about 0 to 30 degrees in order to optimallyexpand the mandrel launcher 150 and tubular member 155 in the radialdirection. In a preferred embodiment, the surface of the conic sectionranges from about 58 to 62 Rockwell C in order to optimally provide highyield strength. In a preferred embodiment, the expansion cone 145 isheat treated in order to optimally provide a hard outer surface and aresilient interior body in order to optimally provide abrasionresistance and fracture toughness. In an alternative embodiment, themandrel 145 is expandible in order to further optimally augment theradial expansion process.

[0036] The mandrel launcher 150 is coupled to the support member 105,the mandrel 145, and the tubular member 155. The mandrel launcher 150preferably are a tubular member having a variable cross-section and areduced wall thickness in order to facilitate the radial expansionprocess. In a preferred embodiment, the cross-sectional area of themandrel launcher 150 at one end is adapted to mate with the mandrel 145,and at the other end, the cross-sectional area of the mandrel launcher150 is adapted to match the cross-sectional area of the tubular member155. In a preferred embodiment, the wall thickness of the mandrellauncher 150 ranges from about 50 to 100% of the wall thickness of thetubular member 155 in order to facilitate the initiation of the radialexpansion process.

[0037] The mandrel launcher 150 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low allow steel, stainless steel, orcarbon steel. In a preferred embodiment, the mandrel launcher 150 isfabricated from oilfield country tubular goods having higher strengthbut lower wall thickness than the tubular member 155 in order tooptimally match the burst strength of the tubular member 155. In apreferred embodiment, the mandrel launcher 150 is removably coupled tothe tubular member 155. In this manner, the mandrel launcher 150 may beremoved from the wellbore 180 upon the completion of an extrusionoperation.

[0038] In an alternative embodiment, the support member 105 and themandrel launcher 150 are integrally formed. In this alternativeembodiment, the support member 105 preferably terminates above the topof the packer 110. In this alternative embodiment, the fluid conduits115 and/or 135 provide structural support for the apparatus 100, usingthe packer 110 to couple together the elements of the apparatus 100. Inthis alternative embodiment, in a preferred embodiment, during theradial expansion process, the packer 110 may be unset and reset, afterthe slips 160 have anchored the tubular member 155 to the previouscasing 170, within the tubular member 155, between radial expansionoperations. In this manner, the packer 110 is moved downhole and theapparatus 100 is re-stroked.

[0039] The tubular member 155 is coupled to the mandrel launcher, theslips 160 and the seals 165. The tubular member 155 preferably is atubular member fabricated from any number of conventional commerciallyavailable materials such as, for example, low alloy steel, carbon steel,stainless steel, or oilfield country tubular goods. In a preferredembodiment, the tubular member 155 is fabricated from oilfield countrytubular goods.

[0040] The slips 160 are coupled to the outside surface of the tubularmember 155. The slips 160 preferably are adapted to couple to theinterior walls of a casing, pipeline or other structure upon the radialexpansion of the tubular member 155. In this manner, the slips 160provide structural support for the expanded tubular member 155. Theslips 160 may be any number of conventional commercially available slipssuch as, for example, RTTS packer tungsten carbide slips, RTTS packerwicker type mechanical slips or Model 3L retrievable bridge plugtungsten carbide upper mechanical slips. In a preferred embodiment, theslips 160 are RTTS packer tungsten carbide mechanical slips availablefrom Halliburton Energy Services. In a preferred embodiment, the slips160 are adapted to support axial forces ranging from about 0 to 750,000lbf.

[0041] The seals 165 are coupled to the outside surface of the tubularmember 155. The seals 165 preferably provide a fluidic seal between theoutside surface of the expanded tubular member 155 and the interiorwalls of a casing, pipeline or other structure upon the radial expansionof the tubular member 155. In this manner, the seals 165 provide afluidic seal for the expanded tubular member 155. The seals 165 may beany number of conventional commercially available seals such as, forexample, nitrile rubber, lead, Aflas rubber, Teflon, epoxy, or otherelastomers. In a preferred embodiment, the seals 165 are rubber sealsavailable from numerous commercial vendors in order to optimally providepressure sealing and load bearing capacity.

[0042] During operation of the apparatus 100, the apparatus 100 ispreferably lowered into a wellbore 180 having a preexisting section ofwellbore casing 170. In a preferred embodiment, the apparatus 100 ispositioned with at least a portion of the tubular member 155 overlappingwith a portion of the wellbore casing 170. In this manner, the radialexpansion of the tubular member 155 will preferably cause the outsidesurface of the expanded tubular member 155 to couple with the insidesurface of the wellbore casing 170. In a preferred embodiment, theradial expansion of the tubular member 155 will also cause the slips 160and seals 165 to engage with the interior surface of the wellbore casing170. In this manner, the expanded tubular member 155 is provided withenhanced structural support by the slips 160 and an enhanced fluid sealby the seals 165.

[0043] As illustrated in FIG. 1b, after placement of the apparatus 100in an overlapping relationship with the wellbore casing 170, a fluidicmaterial 185 is preferably pumped into the chamber 175 using the fluidpassage 120 and the inlet passages 125. In a preferred embodiment, thefluidic material is pumped into the chamber 175 at operating pressuresand flow rates ranging from about 0 to 9,000 psi and 0 to 3,000gallons/minute in order to optimally provide flow rates and operationalpressures for the radial expansion process. The pumped fluidic material185 increase the operating pressure within the chamber 175. Theincreased operating pressure in the chamber 175 then causes the mandrel145 to extrude the mandrel launcher 150 and tubular member 155 off ofthe face of the mandrel 145. The extrusion of the mandrel launcher 150and tubular member 155 off of the face of the mandrel 145 causes themandrel launcher 150 and tubular member 155 to expand in the radialdirection. Continued pumping of the fluidic material 185 preferablycauses the entire length of the tubular member 155 to expand in theradial direction.

[0044] In a preferred embodiment, the pumping rate and pressure of thefluidic material 185 is reduced during the latter stages of theextrusion process in order to minimize shock to the apparatus 100. In apreferred embodiment, the apparatus 100 includes shock absorbers forabsorbing the shock caused by the completion of the extrusion process.

[0045] In a preferred embodiment, the extrusion process causes themandrel 145 to move in an axial direction 185. During the axial movementof the mandrel, in a preferred embodiment, the fluid passage 140 conveysfluidic material 190 displaced by the moving mandrel 145 out of thewellbore 180. In this manner, the operational efficiency and speed ofthe extrusion process is enhanced.

[0046] In a preferred embodiment, the extrusion process includes theinjection of a hardenable fluidic material into the annular regionbetween the tubular member 155 and the bore hole 180. In this manner, ahardened sealing layer is provided between the expanded tubular member155 and the interior walls of the wellbore 180.

[0047] As illustrated in FIG. 1c, in a preferred embodiment, upon thecompletion of the extrusion process, the support member 105, packer 110,first fluid conduit 115, annular seal 130, second fluid conduit 135,mandrel 145, and mandrel launcher 150 are moved from the wellbore 180.

[0048] In an alternative embodiment, the apparatus 100 is used to repaira preexisting wellbore casing or pipeline. In this alternativeembodiment, both ends of the tubular member 155 preferably include slips160 and seals 165.

[0049] In an alternative embodiment, the apparatus 100 is used to form atubular structural support for a building or offshore structure.

[0050] Referring now to FIGS. 2a, 2 b, 2 c, 2 d, and 2 e, an apparatus200 for expanding a tubular member will be described. In a preferredembodiment, the apparatus 200 includes a support member 205, a mandrellauncher 210, a mandrel 215, a first fluid passage 220, a tubular member225, slips 230, seals 235, a shoe 240, and a second fluid passage 245.In a preferred embodiment, the apparatus 200 is used to radially expandthe mandrel launcher 210 and tubular member 225. In this manner, theapparatus 200 may be used to form a wellbore casing, line a wellborecasing, form a pipeline, line a pipeline, form a structural supportmember, or repair a wellbore casing, pipeline or structural supportmember. In a preferred embodiment, the apparatus 200 is used to clad atleast a portion of the tubular member 225 onto a preexisting structuralmember.

[0051] The support member 205 is preferably coupled to the mandrellauncher 210. The support member 205 preferably is a tubular memberfabricated from any number of conventional commercially availablematerials such as, for example, oilfield country tubular goods, lowalloy steel, carbon steel, or stainless steel. The support member 205,the mandrel launcher 210, the tubular member 225, and the shoe 240 arepreferably selected to fit through a preexisting section of wellborecasing 250. In this manner, the apparatus 200 may be positioned withinthe wellbore casing 270. In a preferred embodiment, the support member205 is releasably coupled to the mandrel launcher 210. In this manner,the support member 205 may be decoupled from the mandrel launcher 210upon the completion of an extrusion operation.

[0052] The mandrel launcher 210 is coupled to the support member 205 andthe tubular member 225. The mandrel launcher 210 preferably are atubular member having a variable cross-section and a reduced wallthickness in order to facilitate the radial expansion process. In apreferred embodiment, the cross-sectional area of the mandrel launcher210 at one end is adapted to mate with the mandrel 215, and at the otherend, the cross-sectional area of the mandrel launcher 210 is adapted tomatch the cross-sectional area of the tubular member 225. In a preferredembodiment, the wall thickness of the mandrel launcher 210 ranges fromabout 50 to 100% of the wall thickness of the tubular member 225 inorder to facilitate the initiation of the radial expansion process.

[0053] The mandrel launcher 210 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low allow steel, stainless steel, orcarbon steel. In a preferred embodiment, the mandrel launcher 210 isfabricated from oilfield country tubular goods having higher strengthbut lower wall thickness than the tubular member 225 in order tooptimally match the burst strength of the tubular member 225. In apreferred embodiment, the mandrel launcher 210 is removably coupled tothe tubular member 225. In this manner, the mandrel launcher 210 may beremoved from the wellbore 260 upon the completion of an extrusionoperation.

[0054] The mandrel 215 is coupled to the mandrel launcher 210. Themandrel 215 preferably are an annular member having a conic sectionfabricated from any number of conventional commercially availablematerials such as, for example, machine tool steel, ceramics, tungstencarbide, titanium or other high strength alloys. In a preferredembodiment, the angle of the conic section of the mandrel 215 rangesfrom about 0 to 30 degrees in order to optimally expand the mandrellauncher 210 and the tubular member 225 in the radial direction. In apreferred embodiment, the surface of the conic section ranges from about58 to 62 Rockwell C in order to optimally provide high yield strength.In a preferred embodiment, the expansion cone 215 is heat treated inorder to optimally provide a hard outer surface and a resilient interiorbody in order to optimally provide abrasion resistance and fracturetoughness. In an alternative embodiment, the mandrel 215 is expandiblein order to further optimally augment the radial expansion process.

[0055] The fluid passage 220 is positioned within the mandrel 215. Thefluid passage 220 is preferably adapted to convey fluidic materials suchas cement, water, epoxy, lubricants, and slag mix at operating pressuresand flow rates ranging from about 0 to 9,000 psi and 0 to 3,000gallons/minute in order to optimally provide flow rates and operationalpressures for the radial expansion process. The fluid passage 220preferably includes an inlet 265 adapted to receive a plug, or othersimilar device. In this manner, the interior chamber 270 above themandrel 215 may be fluidicly isolated from the interior chamber 275below the mandrel 215.

[0056] The tubular member 225 is coupled to the mandrel launcher 210,the slips 230 and the seals 235. The tubular member 225 preferably is atubular member fabricated from any number of conventional commerciallyavailable materials such as, for example, low alloy steel, carbon steel,stainless steel, or oilfield country tubular goods. In a preferredembodiment, the tubular member 225 is fabricated from oilfield countrytubular goods.

[0057] The slips 230 are coupled to the outside surface of the tubularmember 225. The slips 230 preferably are adapted to couple to theinterior walls of a casing, pipeline or other structure upon the radialexpansion of the tubular member 225. In this manner, the slips 230provide structural support for the expanded tubular member 225. Theslips 230 may be any number of conventional commercially available slipssuch as, for example, RTTS packer tungsten carbide mechanical slips,RTTS packer wicker type mechanical slips, or Model 3L retrievable bridgeplug tungsten carbide upper mechanical slips. In a preferred embodiment,the slips 230 are adapted to support axial forces ranging from about 0to 750,000 lbf.

[0058] The seals 235 are coupled to the outside surface of the tubularmember 225. The seals 235 preferably provide a fluidic seal between theoutside surface of the expanded tubular member 225 and the interiorwalls of a casing, pipeline or other structure upon the radial expansionof the tubular member 225. In this manner, the seals 235 provide afluidic seal for the expanded tubular member 225. The seals 235 may beany number of conventional commercially available seals such as, forexample, nitrile rubber, lead, Aflas rubber, Teflon, epoxy or otherelastomers. In a preferred embodiment, the seals 235 are conventionalrubber seals available from various commercial vendors in order tooptimally provide pressure sealing and load bearing capacity.

[0059] The shoe 240 is coupled to the tubular member 225. The shoe 240preferably is a substantially tubular member having a fluid passage 245for conveying fluidic materials from the chamber 275 to the annularregion 270 outside of the apparatus 200. The shoe 240 may be any numberof conventional commercially available shoes such as, for example, aSuper Seal II float shoe, a Super Seal II Down-Jet float shoe, or aguide shoe with a sealing sleeve for a latch down plug modified inaccordance with the teachings of the present disclosure. In a preferredembodiment, the shoe 240 is an aluminum down-jet guide shoe with asealing sleeve for a latch down plug, available from Halliburton EnergyServices, modified in accordance with the teachings of the presentdisclosure, in order to optimally guide the tubular member 225 in thewellbore, optimally provide a fluidic seal between the interior andexterior diameters of the overlapping joint between the tubular members,and optimally facilitate the complete drilling out of the shoe and plugupon the completion of the cementing and radial expansion operations.

[0060] During operation of the apparatus 200, the apparatus 200 ispreferably lowered into a wellbore 260 having a preexisting section ofwellbore casing 275. In a preferred embodiment, the apparatus 200 ispositioned with at least a portion of the tubular member 225 overlappingwith a portion of the wellbore casing 275. In this manner, the radialexpansion of the tubular member 225 will preferably cause the outsidesurface of the expanded tubular member 225 to couple with the insidesurface of the wellbore casing 275. In a preferred embodiment, theradial expansion of the tubular member 225 will also cause the slips 230and seals 235 to engage with the interior surface of the wellbore casing275. In this manner, the expanded tubular member 225 is provided withenhanced structural support by the slips 230 and an enhanced fluid sealby the seals 235.

[0061] As illustrated in FIG. 2b, after placement of the apparatus 200in an overlapping relationship with the wellbore casing 275, a fluidicmaterial 280 is preferably pumped into the chamber 270. The fluidicmaterial 280 then passes through the fluid passage 220 into the chamber275. The fluidic material 280 then passes out of the chamber 275,through the fluid passage 245, and into the annular region 270. In apreferred embodiment, the fluidic material 280 is pumped into thechamber 270 at operating pressures and flow rates ranging from about 0to 9,000 psi and 0 to 3,000 gallons/minute in order to optimally provideflow rates and operational pressures for the radial expansion process.in a preferred embodiment, the fluidic material 280 is a hardenablefluidic sealing material in order to form a hardened outer annularmember around the expanded tubular member 225.

[0062] As illustrated in FIG. 2c, at some later point in the process, aball 285, plug or other similar device, is introduced into the pumpedfluidic material 280. In a preferred embodiment, the ball 285 mates withand seals off the inlet 265 of the fluid passage 220. In this manner,the chamber 270 is fluidicly isolated from the chamber 275.

[0063] As illustrated in FIG. 2d, after placement of the ball 285 in theinlet 265 of the fluid passage 220, a fluidic material 290 is pumpedinto the chamber 270. The fluidic material is preferably pumped into thechamber 270 at operating pressures and flow rates ranging from about 0to 9,000 psi and 0 to 3,000 gallons/minute in order to provide optimaloperating efficiency. The fluidic material 290 may be any number ofconventional commercially available materials such as, for example,water, drilling mud, cement, epoxy, or slag mix. In a preferredembodiment, the fluidic material 290 is a non-hardenable fluidicmaterial in order to maximize operational efficiency.

[0064] Continued pumping of the fluidic material 290 increases fluidicmaterial 280 increases the operating pressure within the chamber 270.The increased operating pressure in the chamber 270 then causes themandrel 215 to extrude the mandrel launcher 210 and tubular member 225off of the conical face of the mandrel 215. The extrusion of the mandrellauncher 210 and tubular member 225 off of the conical face of themandrel 215 causes the mandrel launcher 210 and tubular member 225 toexpand in the radial direction. Continued pumping of the fluidicmaterial 290 preferably causes the entire length of the tubular member225 to expand in the radial direction.

[0065] In a preferred embodiment, the pumping rate and pressure of thefluidic material 290 is reduced during the latter stages of theextrusion process in order to minimize shock to the apparatus 200. In apreferred embodiment, the apparatus 200 includes shock absorbers forabsorbing the shock caused by the completion of the extrusion process.In a preferred embodiment, the extrusion process causes the mandrel 215to move in an axial direction 295.

[0066] As illustrated in FIG. 2e, in a preferred embodiment, upon thecompletion of the extrusion process, the support member 205, packer 210,first fluid conduit 215, annular seal 230, second fluid conduit 235,mandrel 245, and mandrel launcher 250 are removed from the wellbore 280.In a preferred embodiment, the resulting new section of wellbore casingincludes the preexisting wellbore casing 275, the expanded tubularmember 225, the slips 230, the seals 235, the shoe 240, and an outerannular layer 4000 of hardened fluidic material.

[0067] In an alternative embodiment, the apparatus 200 is used to repaira preexisting wellbore casing or pipeline. In this alternativeembodiment, both ends of the tubular member 255 preferably include slips260 and seals 265.

[0068] In an alternative embodiment, the apparatus 200 is used to form atubular structural support for a building or offshore structure.

[0069] In a preferred embodiment, the tubular members 105 and 225; shoes240; expansion cone launchers 150 and 210; and expansion cones 145 and215 are provided substantially as described in one or more of thefollowing U.S. patent applications: (1) utility patent applicationnumber ______, attorney docket number 25791.9.02, filed on Nov. 16,1999, which claimed the benefit of the filing date of provisional patentapplication No. 60/108,558, attorney docket number 25791.9, filed onNov. 16, 1998; (2) utility patent application number ______, attorneydocket number 25791.3.02, filed on Dec. 3, 1999, which claimed thebenefit of the filing date of provisional patent application No.60/111,293, attorney docket number 25791.3, filed on Dec. 7, 1998; (3)utility patent application number ______, attorney docket number25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of thefiling date of provisional patent application No. 60/119,611, attorneydocket number 25791.8, filed on Feb. 11, 1999; (4) provisional patentapplication No. 60/121,702, attorney docket number 25791.7, filed onFeb. 25, 1999; (5) provisional patent application No. 60/121,841,attorney docket number 25791.12, filed on Feb. 26, 1999; (6) provisionalpatent application No. 60/121,907, attorney docket number 25791.16,filed on Feb. 26, 1999; (7) provisional patent application No.60/124,042, attorney docket number 25791.11, filed on Mar. 11, 1999; (8)provisional patent application No. 60/131,106, attorney docket number25791.23, filed on Apr. 26, 1999; (9) provisional patent application No.60/137,998, attorney docket number 25791.17, filed on Jun. 7, 1999; (10)provisional patent application No. 60/143,039, attorney docket number25791.26, filed on Jul. 9, 1999; (11) provisional patent application No.60/146,203, attorney docket number 25791.25, filed on Jul. 29, 1999;(12) provisional patent application No. ______, attorney docket number25791.29, filed on Sep. 16, 1999; (13) provisional patent applicationNo. ______, attorney docket number 25791.34, filed on Oct. 12, 1999;(14) provisional patent application No. ______, attorney docket number25791.36, filed on Oct. 12, 1999; (13) provisional patent applicationNo. 60/159,033, attorney docket number 25791.37, filed on Oct. 12, 1999;(15) provisional patent application No. ______, attorney docket number25791.27, filed on Nov. 01, 1999. Applicants incorporate by referencethe disclosures of these applications.

[0070] Although illustrative embodiments of the invention have beenshown and described, a wide range of modification, changes andsubstitution is contemplated in the foregoing disclosure. In someinstances, some features of the present invention may be employedwithout a corresponding use of the other features. Accordingly, it isappropriate that the appended claims be construed broadly and in amanner consistent with the scope of the invention.

What is claimed is:
 1. A method of coupling a tubular member to apreexisting structure, comprising: positioning the tubular member in anoverlapping relationship to the preexisting structure; placing a mandrelwithin the tubular member; pressurizing an annular region within thetubular member above the mandrel; and displacing the mandrel withrespect to the tubular member.
 2. The method of claim 1, furthercomprising: removing fluids within the tubular member that are displacedby the displacement of the mandrel.
 3. The method of claim 2, whereinthe removed fluids pass inside the annular region.
 4. The method ofclaim 1, wherein the volume of the annular region increases.
 5. Themethod of claim 1, further including sealing off the annular region. 6.The method of claim 5, wherein sealing off the annular region includessealing a stationary member and sealing a non-stationary member.
 7. Themethod of claim 1, further including conveying fluids in oppositedirections.
 8. The method of claim 1, further including conveying apressurized fluid and a non-pressurized fluid in opposite directions. 9.The method of claim 1, wherein the pressurizing is provided at operatingpressures ranging from about 0 to 9,000 psi.
 10. The method of claim 1,wherein the pressurizing is provided at flow rates ranging from about 0to 3,000 gallons/minute.
 11. An apparatus for radially expanding atubular member, comprising: a first tubular member; a second tubularmember positioned within the first tubular member; a third tubularmember movably coupled to and positioned within the second tubularmember; a first annular sealing member for sealing an interface betweenthe first and second tubular members; a second annular sealing memberfor sealing an interface between the second and third tubular members;and a mandrel positioned within the first tubular member and coupled toan end of the third tubular member.
 12. The apparatus of claim 11,further including an annular chamber defined by the first tubularmember, the second tubular member, the third tubular member, the firstannular sealing member, the second annular sealing member, and themandrel.
 13. The apparatus of claim 11, further including an annularpassage defined by the second tubular member and the third tubularmember.
 14. The apparatus of claim 11, further including a fluid passagecontained within the third tubular member and the mandrel.
 15. Theapparatus of claim 11, further including one or more sealing memberscoupled to an exterior surface of the first tubular member.
 16. Theapparatus of claim 11, further including: an annular chamber defined bythe first tubular member, the second tubular member, the third tubularmember, the first annular sealing member, the second annular sealingmember, and the mandrel; and an annular passage defined by the secondtubular member and the third tubular member.
 17. The apparatus of claim16, wherein the annular chamber and the annular passage are fluidiclycoupled.
 18. The apparatus of claim 11, further including one or moreslips coupled to the exterior surface of the first tubular member. 19.The apparatus of claim 11, wherein the mandrel includes a conicalsurface.
 20. The apparatus of claim 19, wherein the angle of attack ofthe conical surface ranges from about 0 to 30 degrees.
 21. The apparatusof claim 19, wherein the conical surface has a surface hardness rangingfrom about 58 to 62 Rockwell C.
 22. An apparatus, comprising: a tubularmember; a piston adapted to expand the diameter of the tubular memberpositioned within the tubular member, the piston including a passage forconveying fluids out of the tubular member; and an annular chamberdefined by the piston and tubular member.
 23. The apparatus of claim 22,wherein the piston includes a conical surface.
 24. The apparatus ofclaim 23, wherein the angle of attack of the conical surface ranges fromabout 0 to 30 degrees.
 25. The apparatus of claim 24, wherein theconical surface has a surface hardness ranging from about 58 to 62Rockwell C.
 26. The apparatus of claim 24, wherein the tubular memberincludes one or more sealing members coupled to the exterior surface ofthe tubular member.
 27. An apparatus, comprising: a first tubularmember; and a second tubular member coupled to the first tubular memberby the process of: positioning the second tubular member in anoverlapping relationship to the first tubular member placing a mandrelwithin the second tubular member; pressurizing an annular region withinthe second tubular member above the mandrel; and displacing the mandrelwith respect to the second tubular member.
 28. The apparatus of claim27, wherein the process for coupling the second tubular member to thefirst tubular member further comprises: removing fluids within thesecond tubular member that are displaced by the displacement of themandrel.
 29. The apparatus of claim 28, wherein the removed fluids passinside the annular region.
 30. The apparatus of claim 27, wherein thevolume of the annular region increases.
 31. The apparatus of claim 27,wherein the process for coupling the second tubular member to the firsttubular member further comprises sealing off the annular region.
 32. Theapparatus of claim 31, wherein sealing off the annular region includessealing a stationary member and sealing a non-stationary member.
 33. Theapparatus of claim 27, wherein the process for coupling the secondtubular member to the first tubular member further comprises conveyingfluids in opposite directions.
 34. The apparatus of claim 27, whereinthe process for coupling the second tubular member to the first tubularmember further comprises conveying a pressurized fluid and anon-pressurized fluid in opposite directions.
 35. The apparatus of claim27, wherein the pressurizing is provided at operating pressures rangingfrom about 0 to 9,000 psi.
 36. The apparatus of claim 27, wherein thepressuring is provided at flow rates ranging from about 0 to 3,000gallons/minute.
 37. The apparatus of claim 27, wherein the first tubularmember includes a defective portion; and wherein the second tubularmember is positioned in opposing relation to the defective portion. 38.A method of coupling a tubular member to a preexisting structure,comprising: preforming the tubular member to include a first portion, asecond portion and a third portion; placing a mandrel within the secondportion of the tubular member; positioning the tubular member in anoverlapping relationship to the preexisting structure; pressurizing aninterior region within the tubular member above the mandrel; anddisplacing the mandrel with respect to the tubular member; wherein theinside diameter of the second portion of the tubular member is greaterthan the inside diameters of the first and third portions of the tubularmember.
 39. The method of claim 38, wherein the pressurizing is providedat operating pressures ranging from about 0 to 9,000 psi.
 40. The methodof claim 38, wherein the pressurizing is provided at flow rates rangingfrom about 0 to 3,000 gallons/minute.
 41. The method of claim 38,wherein the tubular member is expanded beginning at an upper portion ofthe tubular member.
 42. An apparatus for radially expanding a tubularmember, comprising: a first tubular member; a second tubular membercoupled to the first tubular member; a third tubular member coupled tothe second tubular member; and a mandrel positioned within the secondtubular member and coupled to an end portion of the third tubularmember; wherein the inside diameter of the second tubular member isgreater than the inside diameters of the first and third tubularmembers.
 43. The apparatus of claim 42, wherein the mandrel includes afluid passage having an inlet adapted to receive fluid stop member. 44.The apparatus of claim 42, further including one or more slips coupledto the exterior surface of the third tubular member.
 45. The apparatusof claim 42, wherein the mandrel includes a conical surface.
 46. Theapparatus of claim 45, wherein the angle of attack of the conicalsurface ranges from about 0 to 30 degrees.
 47. The apparatus of claim45, wherein the conical surface has a surface hardness ranging fromabout 58 to 62 Rockwell C.
 48. An apparatus, comprising: a tubularmember having a first portion, a second portion, and a third portion;and a piston adapted to expand the diameter of the tubular memberpositioned within the second portion of the tubular member, the pistonincluding a passage for conveying fluids out of the tubular member;wherein the inside diameter of the second portion of the tubular memberis greater than the inside diameters of the first and third portions ofthe tubular member.
 50. The apparatus of claim 49, wherein the pistonincludes a conical surface.
 51. The apparatus of claim 50, wherein theangle of attack of the conical surface ranges from about 0 to 30degrees.
 52. The apparatus of claim 50, wherein the conical surface hasa surface hardness ranging from about 58 to 62 Rockwell C.
 53. Theapparatus of claim 49, wherein the tubular member includes one or moresealing members coupled to the exterior surface of the tubular member.54. An apparatus, comprising: a preexisting structure; and a tubularmember coupled to the preexisting structure by the process of:preforming the tubular member to include a first portion, a secondportion and a third portion; placing a mandrel within the second portionof the tubular member; positioning the tubular member in an overlappingrelationship to the preexisting structure; pressurizing an interiorregion within the tubular member above the mandrel; and displacing themandrel with respect to the tubular member; wherein the inside diameterof the second portion of the tubular member is greater than the insidediameters of the first and third portions of the tubular member.
 55. Theapparatus of claim 54, wherein the pressurizing is provided at operatingpressures ranging from about 0 to 9,000 psi.
 56. The method of claim 54,wherein the pressurizing is provided at flow rates ranging from about 0to 3,000 gallons/minute.
 57. A method of coupling a tubular member to apreexisting structure, comprising: positioning the tubular member in anoverlapping relationship to the preexisting structure; placing a mandrelwithin the tubular member; sealing off an annular region within thetubular member above the mandrel by sealing a stationary member andsealing a non-stationary member; pressurizing the annular region;displacing the mandrel with respect to the tubular member and removingfluids within the tubular member that are displaced by the displacementof the mandrel by passing the removed fluids inside of the annularregion.
 58. An apparatus for coupling a tubular member to a preexistingstructure, comprising: means for positioning the tubular member in anoverlapping relationship to the preexisting structure; means for placinga mandrel within the tubular member; means for sealing off an annularregion within the tubular member above the mandrel by sealing astationary member and sealing a non-stationary member; means forpressurizing the annular region; means for displacing the mandrel withrespect to the tubular member; and means for removing fluids within thetubular member that are displaced by the displacement of the mandrel bypassing the removed fluids inside of the annular region.
 59. Anapparatus for radially expanding a tubular member, comprising: a firsttubular member; a second tubular member positioned within the firsttubular member; a third tubular member movably coupled to and positionedwithin the second tubular member; a first annular sealing member forsealing an interface between the first and second tubular members; asecond annular sealing member for sealing an interface between thesecond and third tubular members; a mandrel positioned within the firsttubular member and coupled to an end of the third tubular member; anannular chamber defined by the first tubular member, the second tubularmember, the third tubular member, the first annular sealing member, thesecond annular sealing member, and the mandrel; a fluid passage definedby the third tubular member and the mandrel fluidicly coupled to aninterior region of the first tubular member below the mandrel; and anannular passage defined by the second tubular member and the thirdtubular member fluidicly coupled to the annular chamber.
 60. Anapparatus, comprising: a first tubular member; and a second tubularmember coupled to the first tubular member by the process of:positioning the second tubular member in an overlapping relationship tothe first tubular member; placing a mandrel within the second tubularmember; sealing off an annular region within the second tubular memberabove the mandrel by sealing a stationary member and sealing anon-stationary member; pressurizing the annular region; displacing themandrel with respect to the second tubular member; and removing fluidswithin the second tubular member that are displaced by the displacementof the mandrel by passing the removed fluids inside of the annularregion.
 61. A method of coupling a tubular member to a preexistingstructure, comprising: preforming the tubular member to include a firstportion, a second portion and a third portion; placing a mandrel withinthe second portion of the tubular member; positioning the tubular memberin an overlapping relationship to the preexisting structure;pressurizing an interior region within the tubular member above themandrel; and displacing the mandrel with respect to the tubular member;wherein the inside diameter of the second portion of the tubular memberis greater than the inside diameters of the first and third portions ofthe tubular member; wherein the pressurizing is provided at operatingpressures ranging from about 0 to 9,000 psi; and wherein thepressurizing is provided at flow rates ranging from about 0 to 3,000gallons/minute.
 62. An apparatus for coupling a tubular member to apreexisting structure, comprising: means for preforming the tubularmember to include a first portion, a second portion and a third portion;means for placing a mandrel within the second portion of the tubularmember; means for positioning the tubular member in an overlappingrelationship to the preexisting structure; means for pressurizing aninterior region within the tubular member above the mandrel; and meansfor displacing the mandrel with respect to the tubular member; whereinthe inside diameter of the second portion of the tubular member isgreater than the inside diameters of the first and third portions of thetubular member; wherein the means for pressurizing is provided atoperating pressures ranging from about 0 to 9,000 psi; and wherein themeans for pressurizing is provided at flow rates ranging from about 0 to3,000 gallons/minute.
 63. An apparatus for radially expanding a tubularmember, comprising: a first tubular member; a second tubular membercoupled to the first tubular member; a third tubular member coupled tothe second tubular member; one or more slips coupled to the exteriorsurface of the third tubular member; and a mandrel having a conicalouter surface including an angle of attack between about 0 to 30 degreesand a surface hardness ranging from about 58 to 62 Rockwell C positionedwithin the second tubular member and coupled to an end portion of thethird tubular member; wherein the inside diameter of the second tubularmember is greater than the inside diameters of the first and thirdtubular members; wherein the mandrel includes a fluid passage having aninlet adapted to receive fluid stop member.
 64. An apparatus,comprising: a preexisting structure; and a tubular member coupled to thepreexisting structure by the process of: preforming the tubular memberto include a first portion, a second portion and a third portion;placing a mandrel within the second portion of the tubular member;positioning the tubular member in an overlapping relationship to thepreexisting structure; pressurizing an interior region within thetubular member above the mandrel; and displacing the mandrel withrespect to the tubular member; wherein the inside diameter of the secondportion of the tubular member is greater than the inside diameters ofthe first and third portions of the tubular member; wherein thepressurizing is provided at operating pressures ranging from about 0 to9,000 psi; and wherein the pressurizing is provided at flow ratesranging from about 0 to 3,000 gallons/minute